The goal of this project is to develop the design and manufacturing processes that are required for welded tube membrane panels in power boilers for Advanced Ultra Supercritical (AUSC) steam cycles. This effort is required prior to an AUSC Component Test (AUSC ComTest) facility to demonstrate high temperature, high pressure (up to 760 degrees Celsius (1400 degrees Fahrenheit) and 35MPa (5000psi) steam conditions. Steam cycles operating at AUSC steam conditions can achieve a 10 percent increase in efficiency above current commercially available state-of-the-art USC boiler steam cycles at 29MPa/605 ºC/620 ºC (4200 psi/1121 ºF/1150 ºF).

The expected results of the project is a fabricated and heat treated prototype welded tube membrane panel that designed and manufactured for long term (30 years or longer )use at the elevated temperatures and pressures of AUSC steam cycles. The results of this project could also be applied to manufacturing similar assemblies in other advanced fossil energy technologies operating at elevated temperatures and pressures.

Project Benefits

Development of high-performance materials technology could lead to higher efficiency fossil energy power plants of more than a 10% increase in efficiency above today’s state-of-the-art boiler steam cycles. The project is intended to develop and prove the manufacturability of welded tube membrane panels made from high-performance materials suitable for the AUSC steam cycles (greater than 1300 ºF / 4000psi) of a fossil-fired boiler.